Reformable dental guard

ABSTRACT

Improvements in cushioned custom dental guard to be constructed with EVA instead of Polyshok. The molding process ensures that the mouth guard provides even fit on all of the teeth. The custom fit is performed by taking an impression of the upper teeth and gums of the user. The dental guard can then be constructed to ensure a proper custom fit. Each layer provides a different function to provide an ideal cushion, as well as integration of artwork that is visible through the front of the dental guard. The dental guard may include air cells or chambers. The air cells provide a cushion by compressing the air cells to absorb an impact and spread the force of the impact over a greater area.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of applicant's provisional application Ser. No. 61/865,051 filed Aug. 12, 2013 the entire contents of which is hereby expressly incorporated by reference herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to improvements in a dental guard. More particularly, the present reformable dental guard is built-up as a layering process to provide cushioning from impacts that can occur while participating in contact sports.

2. Description of Related Art including information disclosed under 37 CFR 1.97 and 1.98

Athletes that participate in contact sports, for example football players, boxers and basketball players, are exposed to trauma from facial blows which may cause damage to the individual. Head blows cause motion between the upper and lower jaw that can result in trauma. To reduce the hazards of such facial trauma injuries, protective mouth guards have been developed for use by athletes and others. Protective mouth guards for athletes generally fall into three types.

All the retail boil and bite mouth guards in the market today are machine made injected molded. Because of this fact, material limitations prevent individuals to achieve a truly secure fitted mouth guard from any boil and bite.

There is no dispute that wearing a mouth guard is better than not wearing one. A properly fitted mouth guard gives the best protection that an individual can have. Wearing a custom mouth guard moves the jaw downward and forward creates joint space in the TMJ. Regardless of any technology patents filed, this cushioned space may reduce concussive forces to the temporal area.

The 3 different types of materials used today to manufacture mouth guards are EVA (ethylene vinyl acetate), Polyshok and ProForm. These materials have been vaguely studied over the years and the conclusion has become very debatable as to what is the best material. To date there has been no conclusive data that suggests which material has a higher impact rating.

The major issue is that no one except Polyshok has done any type of testing. There are two different studies that are published and both have 3 of the same authors. The problem with the studies is that they have the opposite conclusion. The first study states that Polyshok has a superior impact energy absorption rate while the second study states that there is no real difference between EVA, Polyshok, and Proform mouth guard materials. Both studies where performed in the same manner at two different times.

Problems with using Polyshok material include but are not limited to the Polyshok material quickly breaking down where the longevity of the mouth guard is significantly decreased by half. The cost of the material is triple the amount of EVA material. Polyshok material still requires the use of clear EVA as the final layer as well as the primary layer because PolyShok does not have a clear material. Polyshok cannot be a single layer material because it will not last if it is either used as the primary layer or the final layer. This also means that any testing that was conducted is not conclusive because once you place another layer on top of Polyshok you have changed the impact absorption properties.

There has been a history of bonding problems between EVA and PolyShok on the last layer where the main issue has been delamination of the two materials.

A number of patents and or publications have been made to address custom molded mouth guards. Examples of patents and or publication that disclose fabrication of custom molded mouth guards include U.S. Pat. No. 7,882,839 that issued on Feb. 8, 2011 to Edward J. Ambis Jr. that improves the ability of the wearer to speak.

U.S. Pat. No. 6,837,246 issued on Jan. 4, 2005 to Anthony G. DeLike discloses a mouth guard with an improved tongue-airway passage to improve the ability of the wearer to breath. The construction of this device is homogeneous and is fabricated from a casting of the wearer's oral cavity.

U.S. Pat. No. 6,691,710 issued on Feb. 17, 2004 to Jon D. Kittelsen et al for a composite mouth guard. The composite mouth guard is constructed from mechanically interlocking pieces. Because some of the composite materials are rigid the mouth guards are made in a variety of finite sizes to fit different size mouths. The fit is not custom made to fit an individual mouth.

What is needed is a dental guard that is custom fabricated to fit the upper teeth of a user. The mouth guard is fabricated using multiple cushioning layers to provide a custom fit of optimal cushioning and improved jaw alignment. The proposed document provides disclosure of such a mouth guard.

BRIEF SUMMARY OF THE INVENTION

It is an object of the reformable dental guard to be constructed with EVA instead of Polyshok. EVA is the industry standard when manufacturing mouth guards and it is a material that has not changed over the past 10 years. EVA material is an unchanging material whether it is heated or boiled, the properties and protection stay the same. When you use the same material throughout the manufacturing process you ensure that delamination rarely occurs

It is an object of the reformable dental guard for the dental guard to be molded for each individual user. The molding process ensures that the mouth guard provides even fit on all of the teeth. The custom fit is performed by taking an impression of the upper teeth and gums of the user. The dental guard can then be constructed to ensure a proper custom fit.

It is another object reformable dental guard to be constructed with layers of material. Each layer provides a different function to provide an ideal cushion, as well as integration of artwork that is visible through the front of the dental guard.

It is another object reformable dental guard to provide air cells or chambers within the dental guard. The air cells provide a cushion by compressing the air cells to absorb an impact and spread the force of the impact over a greater area.

It is another object reformable dental guard to provide a method of manufacturing a boil and bite mouth guard that can be re-boiled and reshaped to fit a subsequent mouth guard to achieve a fit characteristic that of a custom fitted mouth guard. In order to achieve the closest possible fit to a custom mouth guard, you have to manufacture the boil and bite with the dimensions, average surface area, and thickness comparable to that of a custom mouth guard. This will be the design guideline for the mold for which the boil and bite will be used to manufacture.

It is another object reformable dental guard to be created similar to a custom mouth guard where an important step deals with the materials used to manufacture custom mouth guards, when melting point is reached it can conform to dental anatomy and during the cool down process, holds its shape more steady than that of injected molded plastic. No boil and bite manufacturer has ever attempted this manufacturing process due to the intensive process and manual labor it takes to make a custom mouth guard.

It is still another object of the reformable dental guard for the dental guard to accept a standard or custom logo. The logo is embedded into the front of the dental guard such that the artwork can be visible through to opponents.

Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

FIG. 1 shows a comparison of the construction of the reformable mouth guard with other manufacturing processes.

FIG. 2 shows a flow chart of the manufacturing process used to create the reformable dental guard.

FIG. 3 shows a pictorial view of what occurs when a jaw is struck.

FIG. 4 shows a partial cross section of the reformable mouth guard in a user.

FIG. 5 shows a bottom view of the reformable mouth guard on the upper pallet.

FIG. 6 shows a cross sectional view of the reformable mouth guard from FIG. 5.

FIG. 7A and FIG. 7B show images of the mold that is used to form the reusable mouth guard.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a comparison 19 of the construction of the dental guard with other prior art manufacturing processes. The diagrams that are located and referenced throughout this section to help you gain a broader understanding of how the dental custom dental guard differs from boil and bite mouth guard manufacturing companies.

Many companies start with 4 mm material 21 which does not suck into the interproximal contacts very well which in turn can cause a loose fit. Other companies will typically use a use a second layer that is 2 mm or 3 mm thick material 22 which creates bulky mouth guard on the palate of the athlete. At this point, prior art mouth guards put graphics on top of the already approximately 8 mm thick material of material which reduces down to approximately 4-5 mm of thickness. The prior art makes every dental guard in essentially the exact same way and using the exact same material no matter what size mouth of the user.

With custom dental guards, after a dental impression has been obtained a thin clear layer of material is used as a base material 31 of between 1 mm and 2 mm. A second layer 32 is combined to the first layer. The second layer is custom hand layering for thickness control and adding hard layer of protection maintaining 100% bondable surface between layers with no added delaminating risk. Within this layer air pockets or cushions can be included for shock dispersion when applicable or desired. The second layer 32 is then heat treated until it is completely smooth and uniform.

Third Layer 33 is either 2 mm or 3 mm material. This sub assembly of layers has not yet been added to the palate area. The thickness of the material that is used is based on the width of the palatal area of each unique user. The fourth or last layer 34 is clear either 2 mm or 1.5 mm depending on the patient's mouth. The improvements are not only with the graphic quality, but also with the manufacturing process.

FIG. 2 shows a flow chart of the manufacturing process used to create the reformable dental guard. First the design mold is placed in the thermoforming unit 80. An EVA sheet is placed on top of the ring 81. The heating mechanism is initiated to heat the EVA material 82.

Once the EVA material sags to approximately 1″ 83 the thermoforming cylinder is lowered 84 to the ring to seal and pressurize the chamber between 70 to 90 psi. When the cooling process is complete, the EVA material is formed on the mold 85. When cool down process is complete, raise the cylinder and remove EVA sheet from mold 86. Excess material that forms on the outside of the design mold is cut and trimmed off of the mold 87.

Any desired graphics or artwork is applied to the 1st layer surface where it is the desired location 88. For some complex graphics additional layers of EVA may be required between different graphic images. If there are no desired graphics decoration, ornamentation or indicia is desired the 1st layer of material is placed back on the mold and the mold is placed back into the thermoforming unit 89.

A second EVA sheet is placed on top of the ring 90. The heating process is initiate with the heating mechanism to heat the second sheet of EVA material 91. Once the material sags to touch mold 92, initiate the thermoforming cylinder to lower towards the ring 93 to seal and pressurize the chamber between 70-90 psi. When cool down process is complete 94, raise the cylinder and remove the 2 layers of formed EVA sheet from the mold 95.

Cut and trim the excess material that formed outside of the design mold 96. Polish the edges so that there are no excess and the edges are rounded and curved. Cutting, trimming, and polishing skillsets are learned in the custom mouth guard arena. Because of the construction of the reusable mouth guard, if the fit is not correct, the mouth guard can be re-boiled and the material will essentially re-flow and allow a person, or a subsequent person to boil and bite the mouth guard to achieve a custom fit mouth guard. The re-heating and bite operation can be repeated numerous times with little or no degradation or compromise in the custom fit.

To form the reformable dental guard in the mouth of a user reformable dental guard is heated in water between 180 and 212 degrees Fahrenheit and then placed into a mouth on upper teeth of a person whereupon the person closes said mouth and forces said upper teeth into the reformable dental guard for create an initial impression into the reformable dental guard. If the user wants to re-form the dental guard or another user want to use the same dental guard the reformable dental guard is again re-boiled where the dental guard will reflow into its original condition where it can conform into the mouth of the user.

FIG. 3 shows a pictorial view of what occurs when a jaw is struck, and FIG. 4 shows a partial cross section of the dental guard in a user. In normal resting mode the mandible 43 is cushioned by the connective tissue 42 to the condyle 41 at the end of the jaw in the socket 40. When an unprotected athlete receives an impact 18 to the lower jaw or chin. The impact is translated 17 through the jaw or mandible 43 and can cause an impact that can hit the brain thereby causing a concussion.

The concussion is the result of the mandible 53 being pushed so hard that the connective tissue 52 is squeezed into the condyle 51 and into the socket 50. From FIG. 3 the mandible 63 is cushioned by the reformable dental guard 60 that cushions the athletes 16 teeth 61 to increase the frictional forces between the teeth to reduce movement of the mandible 63.

FIG. 5 shows a bottom view of another embodiment of the reformable dental guard 60 on the upper pallet. From FIG. 4 the dental guard is formed from the anterior teeth (incisors and canines) 70 to the posterior teeth (molars and bicuspids) 71. Optional air cushions 75 are shown placed between adjacent incisors and canines. In this embodiment seven air cushions are shown, but more or less air cushions 75 are contemplated. Locating the air cushions 75 between the teeth is generally placed because extra space exists between the teeth without increasing the thickness of the dental guard. Placement of the cushion(s) 75 is generally not made between posterior teeth 71 because impacts to this area of the mouth are less common.

FIG. 6 shows a cross sectional view of the dental guard from FIG. 5. A thin clear layer of material is used as a base material 31. A second layer 32 is combined to the first layer. The second layer is custom hand layering for thickness control and adding hard layer of protection maintaining 100% bondable surface between layers with no added delaminating risk. Within this layer air pockets or cushions 75 can be included for shock dispersion when applicable or desired. The second layer 32 is then heat treated until it is completely smooth and uniform. Third Layer 33 is either 2 mm or 3 mm material. This sub assembly of layers has not yet been added to the palate area. The thickness of the material that is used is based on the width of the palatal area of each unique user. The fourth or last layer 34 is clear either 2 mm or 1.5 mm depending on the patient's mouth.

Controlling the thickness of the dental guard is critical to providing comfort and protection. There has been limited published articles on testing that has been performed on mouth guards after a mouth guard has been manufactured. Even the surface area being tested only gives the best representation of the type of impact and simulation as an estimate to the protection.

FIG. 7A shows an inside perspective view of the mold used to make the reformable dental guard, and FIG. 7B shows a bottom perspective view of the reformable dental guard. The bottom 100 of the mold is where the mold sits flat within the thermoforming unit. The sheets of EVA material are placed on the top surface of the mold as might be seen in FIG. 7A. From this top perspective view 7A the mold has a raised outer ridge 103 that forms the general profile where teeth would exist in the mouth of the athlete. A lowered area 104 in the front of the mold provides some clearance between the front teeth. A clearance area 105 in the center of the mold provides clearance for the tongue of the athlete. A ridge 101 and 102 forms the trim area for the gums of an athlete. The vertical wall 106 provides a clearance for the teeth of an athlete.

Thus, specific embodiments of a cushioned reformable dental guard have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. 

1. A reformable dental guard comprising: a first EVA layer that is formed on a mold; said first EVA layer is trimmed; a second EVA layer that is formed on said mold over said first EVA layer; said second EVA layer is trimmed thereby creating a reformable mouth guard.
 2. The reformable dental guard according to claim 1 that further includes heating said first EVA layer prior to said forming on said mold.
 3. The reformable dental guard according to claim 2 wherein said heating is performed until said first EVA layer softens and sags.
 4. The reformable dental guard according to claim 3 wherein after said first EVA layer softens and sags said first EVA layer is brought into contact with said mold.
 5. The reformable dental guard according to claim 4 wherein after said first EVA layer is brought into contact with said mold, a seal is created to draw said first EVA material onto said mold to form and cool said EVA layer onto said mold.
 6. The reformable dental guard according to claim 5 that further includes heating said second EVA layer prior to said forming on said mold.
 7. The reformable dental guard according to claim 6 wherein said heating is performed until said second EVA layer softens and sags.
 8. The reformable dental guard according to claim 7 wherein after said first EVA layer softens and sags said second EVA layer is brought into contact with said mold.
 9. The reformable dental guard according to claim 8 wherein after said second EVA layer is brought into contact with said mold, a seal is created to draw said second EVA material onto said mold to form and cool said EVA layer onto said mold.
 10. The reformable dental guard according to claim 1 wherein said EVA is ethylene vinyl acetate.
 11. The reformable dental guard according to claim 5 that further includes placing a plurality of air cells onto or into said first EVA layer prior to forming said second EVA layer.
 12. The reformable dental guard according to claim 1 wherein said first EVA layer is between 1 and 3 mm in thickness.
 13. The reformable dental guard according to claim 1 wherein said second EVA layer is between 2 and 5 mm in thickness.
 14. The reformable dental guard according to claim 1 that further includes a third layer.
 15. The reformable dental guard according to claim 14 wherein said third layer is selected from a group consisting of graphics, multi-color split and multi-color blend.
 16. The reformable dental guard according to claim 15 that further includes a fourth layer.
 17. The reformable dental guard according to claim 16 wherein said fourth layer is clear and covers said third layer.
 18. The reformable dental guard according to claim 1 wherein when said reformable dental guard is heated in water between 180 and 212 degrees Fahrenheit and then placed into a mouth on upper teeth of a person whereupon said person closes said mouth and forces said upper teeth into said reformable dental guard for create an initial impression into said reformable dental guard.
 19. The reformable dental guard according to claim 18 wherein after said initial impression is formed said reformable dental guard is removed and replaced into said mouth for protection.
 20. The reformable dental guard according to claim 20 wherein if said reformable dental guard is reheatable in water between 180 and 212 degrees Fahrenheit said reformable dental guard will reflow into said reformable dental guard to allow said person or a second person to create at least on subsequent impression. 